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solaris 24PC 30PC

1. FE FS hse seals il REL cani TE Fang code cheer i 3 H waki l No Ie and T kas Tall Fil up 2 Dus Chock wines YES pau ca bbe rint Crack if recep magica ud ET presen such Llak pra nus ected len she zl ar smien Ds kus reel bY aen AT Boece arid erra te dawn an kg dapi C a a re la Qube core an bd Chert CI sura paha FA fatlione axle arem cri kil moet 1 Change mari PCR Chart II Check Domestic Hot Water Operation Open DHW taps ls DHW fow rate at least 2 5 man Check cox water inlet TES pressure Check ard if necessary is F2 or F3 failure YES replace DHW or CH cades shown an kaf merear Check if water filter is cleam Check arl if necessary replace water Thaw eT SIT f ilure code shown on bed YES Check and if necessary replace wrerheal thermostat ALI Gio to Chart IN Page 36 3 Chart ul Check Central Hearing Operation Check nx ib epoxy Ck micas FE bikie nk Shean kal WES Check N22 Gone mea
2. llf position Winter use NOTE Depending on the boiler set up there may be a delay of 45secs before the boiler re fires 2 Central Heating temperature control The position of this control dial will determine the temperature of the water delivered to the radiators The water temperature can be set from a minimum of 30 C anticlockwise stop position to a maximum of 85 C clockwise stop position 3 D H W temperature control The position of this control dial will determine the temperature of the domestic hot water delivered to the taps or shower unit The water temperature can be set from a minimum of 35 C anticlockwise stop position to maximum of 64 clockwise stop position Figure 2 Page 43 r Figure 5 The operational time periods may be set as follows a Rotate the clock actuator mechanisms clockwise by hand until the small black triangle indicates the current time see figure 5 In figure 5 current time is 21 05 a The timer uses 24 hour format e g the time for 1pm the time is 13 00 hrs Q Select the On times by pushing the black tappets to the outside Q Select the Off times by pushing the black tappets towards the centre of the clock E g The clock shown in diagram 2 is set as follows The clock operation can be set by a selection switch The switch has 3 positions Up position The boiler is controlled by the function switch Item 1 i
3. 11 2 The meter governor must be capable of delivering a pressure of either 20mbar for natural gas or 37mbar for propane gas dependant on the gas being used Figure 15a 11 3 On final connection of the gas supply to the boiler the complete gas installation including the 10 16 Provisi fill the boil 0 16 Provisions to fill the boiler and system gas meter must be tested for tightness and purged must be made by the Installer using an approved filling loop The filling loop used must be approved to current water byelaws and fitted as close to the boiler as practicable Page 19 20 12 Filling the System 12 1 The boiler must not be operated without water 12 2 On completion of the boiler installation and ensuring that all water connections are correctly made the boiler may be filled with water via the filling loop not supplied with the boiler Ensure that two manual feed valves and boiler isolation valves are open 12 3 Release the cover cap on the boiler s automatic air vent located on top of the internal pump figure 16 when filling the system Figure 16 12 4 The manual feed valves must be closed and the filling loop disconnected once the pressure sensor sited on the boiler s control panel indicates a system pressure of 1 5bar 12 5 Check that all the water connections throughout the system are sound and bleed each of the heating system s radiators in turn 12 6 Air must be vented from
4. Air gas mixer Air gas mixer ring Supply transformer Expansion Vessel 10 Heat exchanger 11 Ionisation electrode 12 Burner 13 Plastic flue duct 14 Plastic flue safety thermostat 15 Gas valve 16 Diverter Valve 17 DHW temperature sensor 18 Condensate trap 19 Overheat Safety thermostat 20 Secondary Heat Exchanger 2 Condensate drain pipe 22 Central heating temperature sensor 23 Ignition electrode 24 Manual air vent NO Q L A Heating Flow 22mm B D H W Outlet 15mm C Gas Inlet 22mm D Cold Water Inlet 15mm E Heating Return 22mm ZU i s 1 4 08 3 Boiler Characteristics 3 1 The Heat Line boiler 1s a fan flued wall mounted combination boiler that supplies both central heating and mains fed domestic hot water Being room sealed the boiler may be installed in any room without the need for purpose made ventilation However if the boiler is installed in a compartment it Is recommended that the compartment is ventilated for cooling purposes A functional diagram of the boiler s principal components is given in figure 1 page 7 3 2 An electronic control unit consisting of a PCB which includes ignition module provides direct burner ignition and flame supervision along with continuous modulation of the burner s gas supply 3 3 An interface unit which includes boiler adjustment potentiometers and fault d
5. heating control voltage free room thermostat to the boiler the connection plug factory fitted bridge across the room thermostat terminal connectors must be removed If a mains voltage thermostat 1s to be used the please refer to figure 8 Page 15 16 solqris 24PC 9 3 js i 4 t rk B g D 8 35 z z 54 m Ji az d B z ai 8 m 2 9 3 P MM J Tam Ese iyi a TRAS HI T za has x wars WM lt lt 118 4 EE B m E 2 2 0 2 z B ORMES Y 0 TRANS f 050058 BISHER Important Note Connection to the mains electrical supply must be maintained at all times in order to provide domestic hot water frost protection anti seizure protection of the pump and pump over run facility Ensure that the boilers electrical supply is not interrupted by any external controls Page 16 10 Boiler Installation 10 1 Manual Handling This appliance is heavy and it is suggested that it should be lifted by two people When manoeuvring the boiler always use safe techniques truck if possible and obtain assistance if required when lifting keep your back straight bend your knees don t twist move your feet Avoid bending forwards or sideways and keep the load as clo
6. As part of the industry wide initiative the boiler comes complete with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current legislation complete all sections relevant to the appliance and installation The details within the Log Book will be required in the event of any warranty work On completion the Log Book which is found on pages 46 amp 47 of the Installation manual must be left with the end user and the relevant sections completed on each subsequent Service visit NOTE You are also obliged to register the installation of this boiler with C O R G I Should you wish to check the SEDBUK website for the rating of this boiler search under DD HEATING or the boiler name and designation e g SOLARIS 24PC For further information or advice UK contact Heatline Service pleases call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 Page 41 42 IMPORTANT INFORMATION The Heat Line boiler 15 a high efficiency gas fired boiler and represents the highest level of technology found in today s gas boiler market In order to maintain peak efficiency along with optimum performance and reliability it Is essential that the boiler be serviced at least once per year by a competent person such as a CORGI Registered Engineer All C O R G I Registered Installers carry a C O R G I ID card and have a regist
7. Installation Servicing amp User Instructions solqris 24PC Natural Gas e Heating amp Hotwater Heatline Solaris 24PC 30PC Pre mix Condensing Ind ustry Combination Boiler Coun ci British Gas Service Listing Solaris 24PC G C No 47 157 04 Solaris 30PC G C No 47 157 05 Benchmark Log Book Boiler Registration amp SEDBUK The Heat Line M range of heating boiler are manufactured from high quality materials enabling reliability and As part of Industry wide initiative the boiler comes complete optimum performance with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current legislation complete all sections relevant to the appliance and installation The details within the Log Book will be required in the event of any warranty work On completion the Log Book which is found on pages 46 amp 47 of the Installation manual must be left with the end user and the relevant sections completed on each subsequent Service visit Heat Line are committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings NOTE You are also obliged to register the installation of this Notified Body IMQ 51BP2750 boiler with C O R G I Should you wish to check the SEDBUK CE Directive 90 396 EEC website for the rating of this boiler search under
8. 3003200663 m H Bm 3003200903 M JONISATIONELECTRODE 3003200904 DIVERTERVALVEMOTOR ONLY 300320009 H omens HM DIVERTERVALVE 3003200017 H 5008200928 B Page 39 solqris 24PC SOLARIS 24 30PC Pre mix Condensing Wall Mounted Combination Boiler User Instructions Page 40 41 Natural Gas Heatline Solaris 24PC 30PC Pre mix Condensing Combination Boiler British Gas Service Listing Solaris 24PC G C No 47 157 04 Solaris 30PC G C No 47 157 05 The Heat Line range of heating boiler are manufactured from high quality materials enabling reliability and optimum performance Heat Line are committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings Notified Body IMQ 51BP2750 CE Directive 90 396 EEC CE Directive 92 42 EEC The manufacturer in the continuous process to improve his products reserves the right to modify the data expressed in the present documentation at any time and without prior notice The present documentation is an informative support and it cannot be considered as a contract towards third parties solaris 24PC 30PC WRAS D 45 9 96 PROS Heating amp Hotwater Industry Council Benchmark Log Book Boiler Registration amp SEDBUK
9. 6a amp 6b from your supplier up to a maximum length of 8m The terminal is suitable for a flat or pitched roof 8 6 The connection of the vertical flue system is similar to the Horizontal flue connection However the 80 125 system is connected with screws to the boiler and the vertical extension pipes and roof terminal are connected by clips as shown in figure 6b item 3 solaris 24PC 30PC Note For each additional 90 elbow used the maximum flue length must be reduced by 1 5 m whilst the use of 2 x 45 bends warrants a reduction of 2m Page 14 WARNING ONLY A HEATLINE APPROVED FLUE IS TO BE USED WITH THIS PRODUCT FAILURE TO COMPLY WITH THIS REQUIREMENT WILL INVALIDATE YOUR GUARANTEE AND MAY LEAD TO A DANGEROUS SITUATION Figure 6a solqris 24PC Figure 6b 9 5 Mains powered thermostats must be connected directly to the mains circuit board as indicated in Figure 6 9 6 Ensure that the polarity of the mains connection is correct as reversed polarity may cause the appliance to malfunction 9 7 While the boiler s main PCB pump three way valve and gas valve are supplied at 230V a c all other components and associated circuits are supplied at low voltage Without room With room thermostat fitted thermostat fitted 9 Electrical Connections 9 1 The boiler is supplied factory wired complete with 1 5 m of mains fly lead All electrical connections to the mains supply must be m
10. Appliance Directive 90 396 EEC O Efficiency Directive 92 42 EEC Low Voltage Directive 73 23 EEC modified from 93 68 and Electromagnetic Compatibility Directive 89 396 EEC modified from 93 68 Heat Line declares that the materials used in the manufacturer of this appliance are non hazardous and that no substances harmful to health are contained within the appliance unsatisfactory performance of the appliance or flue arising from the failure to comply with the installation and user instructions Incorrect installation could invalidate your guarantee and may lead to a dangerous situation If the appliance is sold on to another customer all documentation must be passed on and the appliance re registered with Heatline in order to maintain the guarantee The boiler must be installed in accordance with these instructions and the regulations currently in force Read these instructions carefully before installing or using the appliance Manual Handling As this appliance is heavy it is recommended that you get assistance when lifting When manoeuvring the boiler always use safe techniques keep your back straight bend your knees don t twist move your feet Avoid bending forwards or sideways and keep the load as close to your body as possible Where possible transport the boiler using a suitable trolley sack truck or get some assistance Grip the boiler firmly and before lifting establish where the weight is conce
11. D H W output of 24 kW for Solaris 24 and 30kW for Solaris 30 Consequently once all the connections have been made and the boiler has been filled with water to the designed system operating pressure the boiler may be fired prior to adjustment of its pre set parameters to match the heating systems requirements 14 2 Prior to firing check that the electrical supply to the boiler is On Indication is shown on the LCD display and the gas service cock is in the open position Set the boilers central heating and domestic hot water temperature controls to maximum by turning them fully clockwise Set the external room thermostat if fitted to maximum and set thermostatic radiator valves to maximum 14 3 Switch the boilers function switch to the central heating and domestic hot water position The boilers control unit will now automatically carry out pre ignition safety checks before igniting the burner 14 4 On burner ignition check the integrity of the boilers flue for tightness and correct operation 14 5 Check the boiler for correct domestic hot water operation by opening and closing the household domestic hot water draw off faucet 14 6 In order to maintain the appliance warranty after initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants and dosed with sufficient anti corrosion inhibitor 14 7 Restart the boiler and again allow the
12. DD HEATING CE Directive 92 42 EEC or the boiler name and designation e g SOLARIS 24PC The manufacturer in the continuous process to improve his products reserves the right to modify the data expressed in the present documentation at any time and without prior notice The present documentation is an informative support and it cannot be considered as a contract towards third parties Service please call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 For further information or advice UK contact Heatline Or by E mail on our Web Site www heatline co uk 02 Contents Section Preface 1 Installation Regulations 2 Technical Data 3 Boiler Characteristics 4 Operation 5 General Installation 6 Appliance Siting 7 Flue Terminal Location 9 Flue General 9 Electrical Connections 10 Boiler Installation 11 Gas Supply 12 Filling the System 13 Control Panel Functions 14 Commissioning 2 ele solaris 24PC 30PC 15 Onboard Adjustments 16 Safety Devices 17 Routine Servicing 18 Component Replacement 19 Gas Type Conversion 34 20 Fault Finding Chart Appendices 03 solqris 24PC accepts no responsibility for the The Heat Line Gas fired combination boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations and is deemed to meet the requirements of Gas
13. a dry cloth to polish Do not use abrasive or solvent cleaners solaris 24PC 30PC FURTHER ADVICE For further information or advice UK contact Heatlin Service please call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 Or by E mail at our Web Site on www heatline co uk Page 46 46 OPERATING THE BOILER Prior to operating the boiler check that the pressure reading on the LCD panel lies between 1 and 2 bar Set the boiler s Central Heating and Domestic Hot Water temperature controls to maximum by turning fully clockwise and set the external Room Thermostat if fitted to maximum To set the room thermostat refer to its manufacturer s instructions Switch the boiler s functional switch to the a position The boiler s integral control unit will now automatically carry out pre ignition safety checks before finally igniting the burner The Central Heating and Domestic Hot Water temperature controls and Room Thermostat can now be set to the desired temperature settings When a demand for heat no longer exists the burner will automatically shut down but the green Boiler Stand by indicator will remain alight The boiler will be ready for the next heating demand CLEANING The boiler casing may be cleaned with a damp cloth followed by a dry cloth to polish Do not use abrasive or solvent cleaners solaris 24PC 30PC FURTHER ADVICE Fo
14. page 6 e Note an anti cycle delay time can be set up to a maximum of 255 seconds by adjusting potentiometer 2 as described in section 5 4 on page 27 If you experience any problems please refer to the installation and commissioning guidelines within the boiler instruction manual If necessary please contact Heat Line Enquiries For further information or advice UK contact Heatlin Service please call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 FOR INSTALLERS REMEMBER IT IS A LEGAL REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION solaris 24PC 30PC 5 2 The boiler is designed to operate on fully pumped pressurised sealed systems operating at a maximum of 3bar pressure and maximum design flow temperature of 85 5 3 The boiler s integral expansion vessel is pre charged to a pressure of O 5bar and will accommodate a system volume of 125 at an average water temperature of 75 C and maximum system pressure of 3bar If the system volume is more than 1251 an additional expansion vessel must be fitted to suit the size of the system A Figure 2 Note the filter valve supplied should 561 be fitted to the heating return pipe which is on the extreme rightof the boiler as shown below Boiler Cold water supply Additional expansion vessel if required Filling device H
15. pressure sensor in reverse order ensuring the gasket is correctly fitted Replace the gasket if damaged 18 17 Flow sensor housing a Drain the boiler s hydraulic circuit as detailed in 18 2 Remove the secondary heat exchanger as detailed in 18 9 solaris 24PC 30PC Release the pump outlet pipe nut and rotate the pipe for ease of removal Remove the pump motor and body together with the flow sensor housing as detailed in 18 8 Remove the section of the housing from the pump by releasing the clip Figure 46 18 17 Flow sensor housing Page 32 Drain the boiler s hydraulic circuit as detailed in 18 2 Remove the secondary heat exchanger as detailed in 18 9 Release the pump outlet pipe nut and rotate the pipe for ease of removal Remove the pump motor and body together with the flow sensor housing as detailed in 18 8 Remove the section of the housing from the pump by releasing the clip Disconnect the diverter valve motor electrical connection and remove the motor by releasing the clip as described in 18 20 Release the nut connecting outlet connection to the diverter valve figure 49 33 Figure 49 a Disconnect DHW sensor as described in 18 4 Remove the screw securing the remaining section of the diverter valve to the combination boiler figure 50 Figure 50 Q Fit the replacement diverter valve and flow sensor housing figure 51 in reverse order of rem
16. solaris 24PC 30PC central heating system to reach maximum operating temperature Check that all the water connections throughout the system are sound and bleed each of the heating systems radiators and purpose made air release points in turn 14 8 Check manual air vents and bleed the heat exchanger by means of the screw on the manual air vent 14 9 Check the system pressure and top up if necessary to 1 5bar 14 10 Reset the central heating amp domestic hot water temperature controls and room thermostat to the desired temperature settings Important Notice e Failure to thoroughly power flush the boiler and heating system or to add an anti corrosion inhibitor to the system water will invalidate the boiler s warranty The condensate trap must be filled with water and plastic discharge pipe connected to drain before operating the boiler Page 22 solqris 24PC Potentiometer adjustment cover 15 Onboard Adjustments 15 1 The boiler Incorporates 4 potentiometers and a bank of dip switches to allow adjustment to 1ts pre set parameters These are situated on the rear of the control panel figure 19 _ DIPSWITCHES POTENTIOMETERS 15 2 Setting the maximum c heating flow temperature The boiler is dispatched with a maximum flow temperature factory set to 85 Where a lower maximum temperature is required such as in the case of under floor heating the factory setting can be
17. the boiler s pump by unscrewing the pump s integral vent plug and allowing water to bleed for a few seconds Take care not to allow water to splash onto any electrical components 12 7 When the system is bled of any air the system pressure must be topped until the pressure LCD display indicates a system pressure of 1 5bar 12 8 If the pressure exceeds 1 5bar discharge the excess pressure from the system via a radiator valve or pipe connection Do not use the safety discharge valve as the valve seat solaris 24PC 30PC may become contaminated with debris and fail to re seal Important Note In order to maintain operation and the appliance s warranty after initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants and dosed with sufficient anti 13 Control Panel Functions 13 1 Central heating and D H W temperature controls boiler s integral control unit monitors and adjusts both the boiler s hydraulic circuit and D H W water outlet temperatures by means of sensors located on the C heating and D H W flow outlets The sensors convert the water temperature into an electrical resistance that is relayed back to the control potentiometers 2 amp 3 figure 17 located on the control panel The respective potentiometer control dial allows manual setting of the maximum required temperature reference value between 30 and 85 C for C heat
18. up to 28mm RI Reference should also be made to British Gas Guidance Notes for Installation of Domestic Gas Fired Boilers Due to the manufacturer s continuous improvement policy the manufacturer solaris 24PC 30PC reserves the right to change any specification of the appliance or make modifications to these instructions which meet current regulations at the time of print However the instructions must not be taken as overriding statutory requirements 1 6 ensure reliability and continued performance ensure that other components in the system are also approved to relevant standards and that the appliance and system 1s adequately protected and maintained on an annual basis 1 7 Your boiler comes with a statutory 1 year guarantee In order to claim your 2 years free warranty you must completes and return your guarantee card within one month of the date of Installation or ring the telephone number on the label on the front of your appliance Note Your second year of warranty is only valid if there is evidence of service after the first year of installation It is recommended that the appliance be serviced annually by a competent person as defined in the Gas Safety and Use Regulations and the service record maintained In the Benchmark Logbook For further information or advice UK contact Heatline Service please call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 087
19. valve head full clockwise Open one or more hot water taps to drain boiler circuit Disconnect the cold water inlet connection to the boiler a Clean and inspect the filter replace if necessary as described in 18 18 Re fit the filter and reinstate the cold water inlet connection to the boiler a Fully open the isolating valve on the boiler s cold water inlet and check for leaks 17 12 On completing the service reassemble the boiler components in reverse order ensuring that all component joints and gaskets are sound Any damaged gaskets must be replaced 17 13 Reinstate the boilers electrical and gas supplies and check for gas tightness and correct boiler operation Page 26 2 18 Component Replacement CAUTIO While there are no substances harmful to health contained within this appliance some component parts of the boiler insulation pads gaskets and rope seals are manufactured from man made fibres When damaged or broken these fibres may cause a temporary irritation High dust levels may irritate eyes and upper respiratory system It is important therefore that sensible precautions are applied when exchanging components 18 1 Ensure that both the electrical and gas supplies to the boiler are isolated before replacing any component part 18 2 To prevent the need to drain the entire heating system when replacing the boiler s integral pump expansion vessel safety relief valve and pressure s
20. 0 777 8318 Or E mail via our web site www heatline co uk solqris 24PC Domestic Water Supply P ee Output liters min 17 08 20 10 Capacity Pre Charge bar Flue Extraction r 60 100 mm CO at max Input 30 196 PP Nitrogen oxide NO emissions at max input ppm 20 6 NO Class 5 Nitrogen oxide NO emissions at max input ppm 2 Technical Data Gas inlet pressure G20 kW Heat Input Qinax CH Btu h 25 03 kW Heat Output Btu h 24 42 kWw Heat Input DHW Btu h 31 05 kW Heat Output Pma DHW Btu h 35 01 kW Heat Input CHDHW Btu h 10 00 kW Heat Output Pmin CH DHW Btu h 10 09 Useful efficiency at Useful efficiency at 3096 1074 1075 load x Inlet Pressure 5 Max Max Gas Rate Natural Gas gt 65 32 230 V Power supply Input 50 Hz Max power consumption Level of protection IPX4D Maximum heating C temperature Max domestic hot water C temperature Operating pressure PMS Bar Min 0 8 Domestic water supply PMS 8 pressure Bar Min 0 25 7 0 5 Expansion Vessel 22 26 NO Class 5 temperature max Case Dimensions mm 330d x 430w x 720h G30 G31 VERSION at min input 10 3 0 1906 Watts 140 559 9090 solaris 24PC 30PC D H W Flow Sensor Water Pressure Sensor Pump Pressure Relief Valve Fan
21. 1 Check Ignition System When hei demon E PO ar F or Foe Teck relied saq syra mapesa does Zur ani EE ur failure sheen arid r piep perform pez purpa un 47 replace vi Does sparking sau ai Check srrirg conaeciken Check mar PCH Sumer id placing uf nien mplace o nosey Doe inrer lights YES Eng Ereler try i 1 lirica 1 miran ive via 2 ls failure cole shen en led healer y boring baker X hack di jaz letras poet lien Ew Polar Hgh n Fire paian be Ere oo nad ior YES Chek gussuppry is and karpa prec sah ignia cacy Check aridi ratus nib gsx valec apa id merece Ventus Check iEaprrairy Check arslif mock Check ami essay H LChxkrigkr cian iraire kun clean proba nf electrode Page 38 J9 APPENDICES solaris 24PC Appendix 1 Spare Parts List E 6 AN GASMXERRING RED 3003200659 7 a 7 s PBBOX 3003200084 3003200601 o 3003200780 _ 2003200807 E 9 B PN 30320600 _ LIMIT THERMOSTAT 3003200397 M MANTRANSTORMER 3003200661 B SPARKGENERATOR
22. 1 To enable adequate drainage of the system drain cocks compliant with BS2879 must be fitted at the lowest points in the system pipe work 5 12 To obtain the best hot water performance from your boiler it 1s suggested that the cold water supply to the boiler is taken directly from the incoming mains water supply Note that the boiler will not operate unless there is a minimum pressure of 0 25bar with a flow rate of 2 5l min Where inlet pressures exceed 8bar a pressure regulator must be fitted to the cold water supply 5 13 Where cold water mains are fitted with a water meter check valve s or loose jumper stopcock it is recommended that a domestic hot water mini expansion vessel may need to be fitted solaris 24PC 30PC 5 14 Although the boiler is designed to inhibit the formation of scale in hard water areas above 200mg l a proprietary scale reduced should be fitted in the cold water supply to the boiler 5 15 To obtain the best hot water performance from your boiler it is suggested that supplies to faucets are run in 15mm copper as short as possible and where practical be insulated to reduce heat loss 5 16 The boiler incorporates a frost protection thermostat Therefore if the boiler will not be used for long periods of time during cold weather in order to avoid freezing the electric supply must be left ON and all the central heating isolation valves must be left open The internal frost thermostat will then operate t
23. 4PC 30PC order of removal ensuring the sealing washer is fitted to the pipe connection before tightening Replace the washer if required Figure 45 Using a pressure sensor check that the expansion vessel charge pressure is 0 5 7 5 1 re charge if necessary Open the isolating valves on the flow and return connections refill vent and pressurise the boiler ensuring all joints are sound 18 14 Overheat safety thermostat Page 31 Remove the front panel figure 23 Locate the overheat safety thermostat upstream of the three way valve figure 46 Disconnect the electrical connections from the thermostat Remove the thermostat from the pipe being careful not to damage the retaining clip Fit the replacement thermostat in reverse order to removal Figure 46 24 18 15 Pressure relief valve Drain the boiler s hydraulic circuit as detailed in 18 2 Disconnect the discharge pipe on the outlet of safety valve Disconnect the safety valve from the hydraulic block retaining the o ring for use on reassembly a Fit the replacement safety valve in reverse order to removal and refill vent and pressurise the boiler ensuring all joints are sound J Figure 47 18 16 Pressure sensor a Drain the boiler s hydraulic circuit as detailed in 18 2 a Disconnect and remove the sensor cable and sensor from the flow sensor housing figure 48 a Fit the replacement
24. ade in accordance with the current LE E regulations 9 2 The boiler must be connected to an 9 8 On connecting the mains electrical supply to effective earth system Using the cable the boiler it Is essential to ensure that electrical supplied the boiler may be connected via a 5 safety checks for earth continuity earth resistance amp fused three pin plug to an unswitched polarity and short circuit are carried out prior to making the final connection A diagram of the boiler s electrical circuit is given in figure shuttered socket outlet However 1f the boiler is installed in a room containing a bath or shower regulations dictate that disconnection must be incorporated in the fixed wiring with a switch provided for disconnection from the mains supply having a contact separation of at least 3 mm on all poles and fused at 5 amp 9 9 Fuse Ratings F1 and F2 are 3 15A fast Bertelli amp Partners Circuit Board F1 3 15A fast F2 3 15A fast F3 3 15A f 9 3 The point of connection must be readily accessible at a distance further than 1 5 Board not used adjacent to the appliance and provide complete F1 not used electrical isolation for the boiler and control F2 not used system 9 4 The low voltage room thermostat terminal Warning On no account must any block is located on the back left side of the external voltage be applied to any of the control box figure 7 connection of a terminals on
25. altered between a maximum of 50 and a minimum of 30 by setting dip switch 6 into ON position 15 3 Setting the 45 second delay The boiler is factory set to exclude the delay of 45 seconds before re ignition between the closing of a hot water faucet and CH start up This delay can be set to 45 seconds by setting dip switch 3 Pam figure 19 into the OFF position Figure 19 23456 15 4 255 seconds delay setting The boiler is capable of up to 255 seconds ignition delay anti A nien Emmmnr cycling time before re ignition following burner shut down on the primary hydraulic water reaching its set temperature This delay can be increased up to a maximum of 255 seconds by turning potentiometer P5 Figure 19 clockwise 1 23d 55 The potentiometers can easily be accessed by removing the cover on the rear of control panel Figure 20 However to reach the dip switches the control panel must be opened P7 Ignition fan ramp default setting 4 O clock P5 Anti cycle timer adjustment default setting 6 clock P2 Boiler range adjuster default setting 4 O clock P4 Maximum Fan sped adjustment default setting 4 O clock 15 5 Pump working mode setting The boiler has a factory set to operate the pump for pre purge and post purge times 45 sec This delay can be excluded by fitting dipswitch 2 figure 19 into ON position However this may then cause the boiler ov
26. be installed by a competent person as defined by the Gas Safety Installation and Use Regulations Failure to install this appliance correctly may invalidate your guarantee and may lead to a dangerous situation Your C O R G I registered engineer should carry a C O R G I ID card containing their registration number which should be recorded in your BENCHMARK Log Book which is supplied with the Instructions You can check the validity of this ID number by contacting C O R G I on 0870 401 2300 This appliance must be installed in accordance with the Gas Safety and Use Regulations current Building Regulations Building Standards Scotland 1 5 813 Installation of Gas Appliances Ireland IEE Wiring Regulations BS 7671 Health and Safety Document No 635 Electricity at Work Regulations and Local Water Authority Bye Laws On installation the following British Standards must also be considered Y BS 6798 Specification for installation of gas fired hot water boilers of rated input not exceeding 70k W v BS 5449 Central heating for Domestic Premises Y BS 5546 Installation of gas hot water supplies for domestic purposes BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding 70kW Part 1 Flues BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding Part 2 Air Supply v BS 6891 Installation of low pressure gas pipe work installations
27. cated on the LCD panel DO NOT OVERCHARGE THE BOILER PRESSURE BEYOND 2BAR AS THE BOILER WILL NOT OPERATE The filling loop a flexible hose with two valves should be located below the boiler connecting the second pipe from the right to either one of the outer pipes see figure 10 on page 19 DO NOT CLOSE ANY OF THE FOUR VALVES DIRECTLY CONNECTING TO THE BOILER If the boiler frequently loses pressure then your installer should be consulted Page 45 45 OPERATING THE BOILER Prior to operating the boiler check that the pressure reading on the LCD panel lies between 1 and 2 bar Set the boiler s Central Heating and Domestic Hot Water temperature controls to maximum by turning fully clockwise and set the external Room Thermostat if fitted to maximum To set the room thermostat refer to its manufacturer s instructions Switch the boiler s functional switch to the a position The boiler s integral control unit will now automatically carry out pre ignition safety checks before finally igniting the burner The Central Heating and Domestic Hot Water temperature controls and Room Thermostat can now be set to the desired temperature settings When a demand for heat no longer exists the burner will automatically shut down but the green Boiler Stand by indicator will remain alight The boiler will be ready for the next heating demand CLEANING The boiler casing may be cleaned with a damp cloth followed by
28. d in 18 2 a Disconnect the pipes from the heat exchanger a Release the union connections on the pump and hydraulic block retaining the washers for re assembly replace if damaged a Remove the pump heat exchanger and heat exchanger three way valve connecting pipes Remove the burner as detailed in 17 8 Page 29 30 a Remove the fixing brackets on the heat exchanger shown in figure 40 Figure 40 a Remove the heat exchanger and burner by pulling forward a Fitthe new heat exchanger and reassemble the boiler in reverse order ensuring all washers are fitted Replace any damaged washers or seals as required a Open the isolating valves on the flow and return connections refill vent and re pressurise system ensuring that all joints are sound Check the manual air vent and vent the air from the heat exchanger by means of screw on manual air vent 18 11 Gas valve Ensure that gas supply to boiler is turned off Disconnect the electrical connections to the gas valve and silicone tube Release the main gas supply tube connection from the top of the gas valve and manifold inlet da solaris 24PC 30PC Figure 41 Remove the gas valve s two securing screws and washers from the bottom side of boiler Figure 42 Rotate the gas pipe and withdraw the gas valve assembly taking care not to loose the restrictor in the top of the valve Remove the restrictor and fit
29. eating return 5 4 The heating circuit should be designed and balanced to give a 20 temperature rise across the boiler flow and return 5 5 When fitting a new boiler to an existing system the system must be thoroughly flushed in accordance with the recommendations of BS7593 prior to installation 5 6 It is recommended that the system should be protected by an anticorrosion inhibitor 5 7 On installation it is important to ensure that the heat exchanger is not a natural collection point Page 10 for air and where possible the system pipe work should have a gradient to ensure excess air 15 carried naturally to other purpose made air release points 5 8 The system s water must always be allowed to circulate whenever the circulation pump is running A return by pass must be provided NOTE It is no longer permissible to use non thermostatic radiator valves to allow by pass through a radiator 5 9 In high water volume systems or under floor heating systems where prolonged operation of the boiler is expected at temperatures below 60 a by pass must be installed on the boiler outlet in order to prevent condensation forming inside the boiler body Failure to comply with this requirement will invalidate the manufacturer s guarantee 5 10 The pressure relief discharge must be directed away from any electrical equipment or where it could cause a hazardous situation and terminated in a safe but visible position 5 1
30. ee section 9 4 amp 9 5 for details 3 8 The C H system temperature can be adjusted automatically to balance heat demand dependant on the outside temperature if an outdoor sensor 1s connected directly to the main PCB Call Heatline Technical Services for further assistance 3 9 The boiler incorporates an integrated clock which allows the setting of central heating periods and the boiler s control panel incorporates an LCD display which indicates the state of operation and fault defect codes 4 Operation 4 1 Using the operating switch the boiler can be set to operate either on domestic hot water only or domestic hot water and heating Note Domestic hot water demand draws preference over heating During heating periods the boiler will automatically revert back to heating mode after a draw off of hot water but there will be a 45sec delay if the No 3 dipswitch is set to the OFF position See fig 19 page 27 4 2 Depending on demand water 1s either diverted via the three port valve to the secondary water to water heat exchanger for domestic hot water or directly to the heating system 4 3 DOMESTIC HOT WATER MODE On opening a hot water faucet the boiler automatically responds to fire the boiler and supply the water to water heat exchanger with hot water via the three port valve located on the hydro block boilers electronic control unit automatically modulate the burner s output to maintain the required temperatu
31. emove the expansion vessel releasing the clip on the pump body pipe by Remove the pressure sensor connection as detailed in 18 16 Disconnect the pumps outlet fitting 44 Figure 36 a Remove the fixing screws the pump hydraulic block located at the bottom right of the boiler figure 37 Figure 57 a Remove the pump body assembly Detach the pump body from the hydraulic block by removing the clip a Fit the replacement body in reverse order ensuring that the pump washers are fitted and correct polarity of the electrical connections a Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring the pump union joints are sound 18 9 Secondary Heat Exchanger a Drain the boiler s hydraulic circuit as detailed in 18 2 a Remove the two screws which connect the heat exchanger to the hydraulic block figure 38 solaris 24PC 30PC Figure 38 4 Remove the heat exchanger after removing the diverter valve as described in section P Figure 39 a Fit the new heat exchanger and reassemble the boiler in reverse order ensuring all washers are fitted Replace and damaged washers or seals a Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring all joints are sound 18 10 Primary Heat Exchanger and Burner Q Drain the boiler s hydraulic circuit as detaile
32. ensor the boiler s hydraulic circuit may be isolated from the central heating circuit by closing the boilers isolation valves Opening the drain valve at the back of the pump will then drain the boiler s hydraulic circuit 18 3 For replacement of the following components it will be necessary to remove the boiler casing panels as described in Section 17 18 4 Domestic hot water sensor a The domestic hot water probe is located on the left side of the diverter valve hot water side figure 31 Carefully disconnect the leads from the sensor Remove the sensor using a 13mm spanner a Fit the replacement sensor sealing as required Re fit the leads to the replacement sensor u L 18 solqris 24PC Figure 31 5 Central heating and Flue sensor The Central heating ntc sensor is located on the flow pipe The Flue sensor is located on the plastic flue socket Disconnect the leads from the sensors Remove the sensors from the pipe plastic flue Fit replacement sensors Fit the leads to replacement sensors Central heating NTC sensor Flue NTC sensor 5 ES 18 6 Fan Unit a Remove the burner fan assembly as in 17 8 a Remove the electrical leads from the fan Disconnect the fan a Fit the replacement fan unit in reverse order Page 27 and reconnect all electrical leads before reassembling to the combustion chamber 20 18 7 Printed circuit board PCB Tu
33. er figure 30 Page 25 26 Figure 29 Ignition Ionisation electrodes electrode Figure 50 Premix heat exchanger Burner 17 9 Visually check for debris damage and clean or replace as necessary the following items Heat exchanger Burner Fan compartment Electrodes gt Insulation gaskets gt gt gt IMPORTANT Clean the heat exchanger using a soft brush or vacuum cleaner Do not use any tool likely to damage the finish of the heat the exchanger Clean the burner by washing in soapy water Allow to dry thoroughly before re fitting Do not use wire or sharp instrument to clean the burner ports Ensure the ignition electrode gap is set to 4 mm Ensure the electrodes are 7mm from the burner surface Ensure the Ionisation probe is 8mm from the burner surface solaris 24PC 30PC 17 10 Cleaning the Condensate trap Extract the bottom part of condensate trap by turning anti clockwise If this is difficult to remove then dependant on which trap is used either use an appropriate spanner or pull off the hose from the bottom of the trap and use an appropriate allen key in the socket provided Clean the trap using a household proprietary cleanser preferably containing bleach 17 11 The boiler is fitted with a cold water inlet filter which must be inspected during each service To gain access to the filter a Close the isolating valve on boiler s cold water inlet by turning the
34. er heat thermostat to trip out 15 6 The maximum and minimum heat output for heating is adjusted via potentiometer P2 figure 19 which changes the fan speed and thus the gas rate It is not necessary to make further adjustments Page 23 24 15 7 Ignition fan ramp The graduated opening of the gas valve for ignition rate is governed by the 1 potentiometer P7 control which is factory set to 4 o clock Adjustment from minimum to maximum rate is made by turning the potentiometer fully clockwise 15 8 The boilers integral pump 15 factory set to its maximum speed setting to give a 1000 l hr flow on a nominal 4m head The pump may be adjusted to a lower speed to match the designed c heating system requirements figure 22 Important Dip Switch 4 and Dip Switch 5 figure 19 are factory set and must not be adjusted OH Chart 5 10 1 20 25 3n Q m h 16 Safety Devices 16 1 An hydraulically operated primary pressure sensor monitors water pressure in the primary hydraulic circuit and will flash should the pressure drop below O 8bar and switch off the boiler if the pressure drops below 0 3bar or rises above 3bar The boiler will not operate until the correct system pressure has been correctly re stored and the boiler reset see 15 2 16 2 The temperature of the water flowing from the primary heat exchanger is monitored by an overheat thermostat located on the outlet pipe If the water temperature gets too hot the
35. er must be used when making any adjustments that can affect the combustion characteristics of the boiler this includes converting to a different gas type a Remove the clip connecting the motor to Fit the new air gas mixer ring after the diverter valve figure 54 disconnecting the gas pipe from the gas valve see figure 26 a Adjust dip switch 1 figure 19 to the On Figure 54 position for LPG Off for NG on the main circuit board a Change the diaphragm which is located in the outlet of the gas valve LPG 24kW 4 7mm Brown LPG 30kW 5 35mm Grey NG 24kW 6 5mm Black NG 30kW 7 0mm a Fit the replacement valve in reverse order White ensuring the valve is fitted correctly re assembled check for gas tightness Set the as described in section Zero adjustment following the instructions in section 18 12 noting the correct value for the type of gas that will be used Check the boiler for correct operation x Important Gas type conversion must be completed by attaching the x labels included in the gas conversion kit to the boiler e Type of gas label place in a visible position inside the boiler e Grey label cover the existing gas type on the data plate e nstruction label Position inside the drop down cover on the front of the boiler Page 34 39 NOTE When installing commissioning or servicing a gas a
36. he boiler if the temperature falls too low However if the electrical supply is to be turned off the boiler the heating system and domestic hot water circuit must be drained 6 Appliance Sitting 6 1 If the boiler is to be installed in any room or compartment it requires no purpose made ventilation for combustion air If sited in a room containing a bath or shower then particular reference is drawn to the current LE E Wiring Regulations and local Building Regulations 6 2 The boiler is not suitable for external installation unless protected by a purpose made building such as a boiler house 6 3 The following clearances are recommended for installation purposes 200mm above 300mm below and 20mm at each side 600mm is required at the front but this may be upon opening a cupboard door 6 4 The boiler must be sited at least Im away from flammable materials and combustible walls must be protected with appropriate insulation 6 5 The wall on which the boiler is mounted must be sufficiently strong enough to support the weight of the boiler Page 11 6 6 A condensate drain pipe must be fitted to allow discharge of condensate to a drain or soakway Note condensate is acidic and should be discharged through plastic or suitable corrosion resistant pipes Where possible condensate should be discharged into the household Internal drainage system If this is not practical discharge can be made into an external drain If neither of
37. heating system increases the gas input to the burner decreases conserving energy and increasing efficiency When the demand for heating no longer exists either the room thermostat is satisfied or the heating period has ended the burner will shut down and the boiler will revert to stand by waiting to respond to the next heating demand The integral pump may continue to run after shut down for a short while to dissipate any excess heat within the boiler solaris 24PC 30PC ACCESS TO THE BOILER CONTROLS The boiler controls are found behind the control panel door sited at the bottom of the boiler s front case To open press the doors retaining push catch just above the display screen figure 2 BOILER CONTROLS The function and operation of the main controls located on the control panel fascia figure 3 1s as follows 1 Function switch This is the boilers main operating switch In the position the boiler is In stand by mode and power supply is ON For the boiler to operate the switch must be in the or E position When switched to the E position the boiler will operate only to supply domestic hot water Summer use For the boiler to operate to give both central heating and domestic hot water the switch Please Note When domestic hot water 1s called for during the heating mode the boiler will automatically revert to domestic hot water E mode until the demand for hot water ceases must be
38. iler where the flue connection is made This may cause the fan outlet to get blocked or combustion chamber to fill with debris and will of course cause the boiler to fail to ignite on first ignition It is recommended that you check the fan outlet before you light the boiler Before you fit the boiler ensure that the pipe work that you are installing is connected to the appropriate connections on the boiler i e cold water pipe to cold water inlet hot water outlet to the hot water tap etc Because the boiler is actually operated at the end of each production stage a small amount of water is retained within the boiler when packed Please ensure that you spin the pump rotor manually before firing the boiler Remember to thoroughly flush the water circuits in order to remove any fluxes and debris from them This should be done particularly where boilers are being fitted to existing radiator circuits Refer to BS 7593 1992 for the details to clean DHW and Central heating system This boiler has been factory set and does not require any adjustments to the gas valve or fan speed Remember to release the small cap 1 turn on top of the automatic air vent located on top of the pump before filling This will ensure that air is vented from the pump as the system fills e Do not use the pressure relief valve as a means of flushing the system please use the valve below the pump Discharging water from 5 1 Installer Testing amp Commis
39. ing and 35 and 64 C for D H W When the boiler functions in heating or D H W mode the resistance measured is compared to the manually set reference value The differential determines the modulation of the gas valve adjusting the useful heat output generated and stabilising the temperature to within 1 C 13 2 Re set function Should the boiler lock out at any time please check the gas supply and ionisation probe position the boiler may be re started by turning both the CH amp DHW to minimum switching to the standby position and switching off at the fused spur or socket Switch 4 figure 7 waiting 30 seconds and switching back to its previous position once the fault has been eliminated 13 3 Function switch The three position switch allows the boilers operation to be set to Stand by centre position O Heating D H W left or D H W only right Page 20 21 13 4 LCD display While giving the operational status of the boiler and water temperature to aid in fault diagnostics the control unit has a built in facility that automatically indicates the fault mode If more than one fault simultaneously occurs then only the highest priority fault is displayed Service mode function Turn selector control knob 3 figure 17 3 times between C H setting and the off position no more than 2 seconds between each turn the boiler is now In service mode and will stay there for 15mins turn both C H a
40. into the new valve Refit in reverse order of removal replacing both washers as required Check for gas tightness and correct boiler operation Where necessary the gas valve settings may be re calibrated by the following method 18 12 Zero adjustment setting a Page 30 Insert a combustion analyser into the socket on the flue adapter Remove the brass screw to access the adjustment socket Figure 43 Turn the boilers function switch to the heating hot water position 4 figure 17 Turn the central heating temperature control to maximum setting 2 figure 17 Turn Potentiometers P2 amp P4 figure 19 anticlockwise to the minimum setting 31 a Using a 4mm allen key adjust clockwise to increase the setting anticlockwise to decrease the CO setting by means of a 4mm allen key Natural Gas 9 LPG 10 After adjustment insert the brass screw and re set the potentiometers as follows P7 P2 amp P4 to 4 Figure 45 Feedback silicone pipe Zero adjustment socket 4mm allen key testpoint 18 13 Expansion vessel a Drain the boiler s hydraulic circuit as detailed in 18 2 a Disconnect the pipe coupling on the expansion vessel figure 44 Figure 44 Remove the side panels figure 25 a Remove the securing bracket figure 45 a Lift the pressure vessel out of boiler from the gap over the chasis and fit the replacement vessel to the boiler in reverse solaris 2
41. isplay codes provides easy serviceability of the boiler 3 4 Heat transfer to the boiler s primary hydraulic circuit is obtained via a primary gas to water heat exchanger contained within a hermetically sealed combustion chamber A 24 volt modulated speed fan blows the products of combustion from the combustion chamber to outside air via an associated flue system 3 5 A secondary heat exchanger allows the instantaneous transferral of heat from the primary hydraulic circuit to water destined for domestic hot water use The secondary heat exchanger is sized so as to minimise thermal shock and is protected against the build up of lime scale by limiting the D H W outlet water temperature to a maximum of 60 3 6 An integral pump located in the boilers main hydraulic circuit circulates water through the primary heat exchanger to either the central heating circuit or D H W heat exchanger depending on the demand In the event of reduced or interrupted water circulation in the central heating circuit a system by pass should be fitted in accordance with current legislation as far away from the boiler as possible Note It is no longer solaris 24PC 30PC permissible to utilise a non thermostatic controlled radiator as a by pass 3 7 Room temperature can be controlled by the use of an external room thermostat or temperature regulator Note connection of the room thermostat is dependant on the operating voltage of the thermostat S
42. istance figure 13 from the face of the external wall to the back of boiler s elbow connecting collar The measurement for the inner flue duct will be L 20mm 10 10 Measuring from the back of the terminal connection mark distance L onto the outer air duct figure 13 10 11 Cut the outer air duct only to the required length ensuring that the cut is square and free from burrs External L wall face uc d IT 57759 li 10 12 Measuring from the back of the terminal connection mark distance L 20mm figure 14 onto the inner flue duct and cut the duct to size ensuring that the cut is square and free from burrs 10 13 Pass the flue assembly through the wall and connect the assembly to the boiler ensuring that both the air and flue duct joints are fully pushed home into the connecting elbow s collar 10 14 With the flue tilted at 3 allowing condensate to drain back into the boiler and joints secured fit the flue trim to the external wall surface using a suitable mastic Note Where internal access only is available the flue trim must be attached to the flue assembly prior to passing the assembly through the wall Page 18 solqris 24PC 10 15 The vertical system diagram is shown in If it 18 not practicable to install the filling loop in figure 15a and 15b Note Maximum vertical an obvious position please add a label on the flue length is 8m with a 60 100mm flue boiler to
43. l control unit electronically provides direct burner ignition and combustion supervision along with continuous modulation of the burner s gas supply By means of a manual switch the boiler can be set to operate in one of two operating modes domestic hot water only or domestic hot water and central heating DOMESTIC HOT WATER MODE When hot water demand is requested by the opening of a hot water faucet the boiler will fire automatically An integral pump is then energised and hot water from the boilers primary circuit is circulated through the secondary heat exchanger allowing the instantaneous transferral of heat to the incoming cold water The secondary heat exchanger is protected against an internal build up of lime scale by limiting the hot water temperature at the tap to a maximum of 64 Hot water will continue to flow through the tap until no longer required When the demand for hot water ceases the integral pump may continue to run for a short while to dissipate any excess heat Page 42 within the boiler DOMESTIC HOT WATER AND CENTRAL HEATING MODE When heating demand is requested the boiler will fire automatically An integral pump is then energised and hot water from the boilers primary circuit is circulated around the heating systems pipe work and radiators The heat output from the boiler is automatically adjusted by the boiler s internal control unit to match the heating demand As the water temperature of the
44. mp DHW controls to max this sets the boiler to max output and will not modulate turn both the controls to min to set the boiler on min without modulation for setting up the default parameters solaris 24PC 30PC Figure 18 UYU ry 0 e H Z RESET 11 TT 1 C Heating D H W water temperature and failure code indicator 2 C Heating water pressure value indicator 3 Flame indication 4 Frost protection indicator 5 Service computer connection indicator 6 Failure indicator 7 D H W mode indicator 8 Winter mode indicator Heating amp Hot Water 9 C Heating mode indicator 10 Summer mode indicator Hot Water Only Reset indicator Failure Codes FO The Water Pressure is Too LOW or Too HIGH Lockout due to overheating F2 D H W temperature sensor damage F3 Primary temperature sensor damage F4 Ignition problem F5 Combustion product flue temperature sensor damage F6 External temperature sensor damage F7 Problem with fan feedback signal F8 Fan speed out of set range F9 Fan is moving when it should be stationary OC External sensor is connected and OTC enabled CC External sensor is disconnected and OTC disabled and Flue sensor Page 21 22 14 Commissioning 14 1 The boilers have been tested and pre set at the factory and is dispatched with its on board controls set to provide a maximum central heating and
45. n Figure 3 and allows continuous operation 22 Mid position The boiler heating circuit is controlled by both function switch and clock tappets whilst hot water is delivered on demand Down position The boiler is off independent of the function switch FROST PROTECTION The boiler has a built in frost protection device that protects the boiler from freezing If the boiler 1s to be left and there 1s a risk of frost ensure that the gas and electrical supplies are left connected The frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the solaris 24PC 30PC temperature reaches 15 C the boiler will shut down Note This device works irrespective of any room thermostat setting and will protect the boiler but not necessarily the full system Ensure that vulnerable sections of the circuit are adequately lagged ANTI PUMP SEIZURE Note the pump will occasionally operate automatically in order to avoid seizure See Daren for time specification SYSTEM PRESSURE On installation your installer will have filled the boiler and system to its effective working pressure The boiler s pressure sensor should be regularly checked on the LCD to ensure that this pressure is maintained between 1 and 2 bar If there Is a significant loss in pressure the boiler will lock out The system may be re charged by opening the filling loop to charge the system back up to 1 5bar as indi
46. ning pA fed oc 2 pal man ord by az aspe Check cabin connections of fan arai d neccesary hin Check CH unser amd main a il replace term if Frase HEN aiu Ia nequid d i kcu oh Sue ET T i frusrcuETER nios ai rall Ir F3 cade dire kir eonmeecthom 10 Check fan ami replace lc Ft Go Bere code Mir Check if reccunry shennan cz Wr eta LY AE prec bth od baliran Check ond replace Check ud if ri amp rocranry repre ruin Chart IV Fan Operation is 24 V de presumir fori ix P3 irde L terminals nn bed 1 4 7 Go tr Chan I Check fase X13 Check fine abi and ee ring cor resctiara Chock cleaning of fan Check arii s necgmary replace fan ar E neces reple maia Chart V Check DHW and CH modulation burner arri Marra Carry Check wiring connection to DHW CH sensor Check wiring SEN SOT Check DHW flow sensor and main PCA board necessary Teac them Check Tan arid replace if necessary il necessary Page 37 solaris 24PC 30PC solqris 24PC Chart V
47. ntrated to determine the centre of gravity repositioning yourself if necessary 04 The Signs on Box The sien of approval This appliance has been certified by IMQ 7 This 15 a fragile piece of equipment Do not drop 7 Avoid getting the carton damp or wet 9 5 The packed appliances may be stacked five high m may damage the appliance Store the appliance upright as indicated on the box Do not crush the packaging as this solaris 24PC 30PC Access warnings and connections on the boiler This picture shows the terminal block which is located at the Room Thermostat bottom left hand side of the control panel cover to which the room thermostat must be fitted NOTE This is a voltage free connection and no power must be applied to these terminals For mains powered thermostat connection see section housing warning of high voltages within the control box Turn off and isolate the appliance before removing this cover NOTE Take care as there may be residual voltage within some components Warning High Voltage This sign is located on the back of the control box Potentiometer cover Removal of the cover which is found on the back of the control box gives access to the adjustment potentiometers NOTE Do not make any adjustments without reading the instructions carefully 05 1 Installation Regulations 1 1 1 2 1 5 1 4 1 5 This appliance must
48. oofs 200 mm From vertical drain pipes and soil pipes 150 mm From internal or external corners 300 mm Above ground roof or balcony level 300 mm From a surface facing a terminal 600 mm From a terminal discharging towards another terminal 1200 mm From an opening in a car port e g door window into a dwelling 1200 mm Vertically from a terminal on the same wall 1500 mm Horizontally from a terminal on the same wall 300 mm Above an opening air brick opening windows etc 300 mm Horizontally to an opening air brick opening windows etc 300 mm Above roof level to base of terminal 300 mm Q From adjacent wall to flue 300 mm From an adjacent opening window 1000 mm From another roof terminal 600 mm E o o Internal Corner External Corner Double Corners Page 13 8 Flue General 8 1 The boiler utilises a concentric flue arrangement which consists of a 60mm diameter inner flue and 100mm diameter outer air inlet duct 8 2 A standard 700 5mm flue kit figure 4 is supplied with the boiler which can be routed to the rear left or right of the appliance by means of a 90 degree bend figure 5 The bend is connected to the boiler using the screws provided and sealed with the gasket Figure 4 Figure 5 8 3 The horizontal 60 100cm flue pipes may be extended up to a maximum of 7m using additional spare components available from your supplier 8 4 A vertical 60 100cm flue kit is also available figures
49. oval ensuring all components are assembled correctly Q Open the isolating valves on the flow and return connections refill vent and pressurise boiler ensuring all joints are sound solaris 24PC 30PC 18 18 Filter a Drain the boiler s hydraulic circuit as detailed in 18 2 a Remove the flow sensor housing as described in 18 8 Q Remove the filter on the inlet of the housing Q Clean or fit replacement filter Assemble the components in reverse order of removal ensuring all components are assembled correctly a Open the isolating valves on the flow and return connections refill vent and pressurise the boiler ensuring all joints are sound 18 19 Flow sensor a Remove the flow sensor by using a pair of snipe nose pliers figure 52 Figure 52 a Fit the replacement sensor in reverse order to removal using the cable connector if required Page 33 34 18 20 Diverter valve Figure 44 Ensure that the electric supply to the boiler is isolated from the mains supply solaris 24PC 30PC 19 Gas Conversion Warning Gas conversion must be carried out by a competent person as defined in the Gas Safety Installation Disconnect the electrical connection from and Use Regulations the diverter valve motor figure 53 19 1 If gas conversion is required from NG to LPG etc follow the instructions below using Figure 55 only approved components from your agent a A flue gas analys
50. ppliance that incorporates a pre mix burner and zero set governor because it is not possible to measure an operating pressure the engineer should first check that the gas supply is metered and ascertain whether it 1s possible to measure the gas rate If the gas input rate can be measured then the requirements of GSIUR 2609 can be met including any specific requirements In manufacturers instructions If gas input rate cannot be measured then to satisfy the intent of GSIUR 26 9 the engineer shall measure the combustion quality of the appliance in accordance with BS 7967 or the technical data of this manual If the engineer does not have the required equipment and no alternative test 1s specified by the manufacturer then the appliance shall be turned off and disconnected as an un commissioned appliance until such time that equipment is available to undertake such tests Page 35 solaris 24PC 30PC solqris 24PC 20 Fault Finding Chart Chart T Check electrical supply C H sensor nnd frost protection Chen de Felkre yug before Los x on pared supple iz za Palins fs Pump agau Wir DT dest rude cy mec is forties sz ichu bods on roni aant Iz 111i mc orn 313 7 jiem bz 1 and bar ls od Chock supply Check apply
51. r further information or advice UK contact Heatlin Service please call 0870 777 8341 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 Or by E mail at our Web Site on www heatline co uk Page 46 Heatline Nottingham Road Belper Derbyshire DESO I Tel 01773 596 099 Fax 01773 828 123 Email sales neatline co uk
52. ration number which should be recorded and entered on your benchmark log book You can check your Installer registration by contacting C O R G I on 01256 372300 The boiler s Log Book must be completed at each Service visit GAS SAFETY INSTALLATION AND USE REGULATIONS It is a legal requirement that all gas appliances must be installed and serviced by a competent or C O R G I registered person in accordance with the above regulations Failure to install or service gas appliances correctly may invalidate your guarantee and could lead to prosecution It is in your interest and that of safety to ensure compliance with the law For electrical safety the boiler must be earthed and protected by a 5 amp fuse Note In the event of a fault the appliance should not be used until a competent person has corrected the fault VENTILATION For maintenance and safety purposes the boiler has been installed with a minimum space of 200mm above 300mm below 600mm to the front and 20mm to either side of the boiler case It is essential that this space 15 not restricted by the addition of shelves etc fitted above or below the boiler or to the solaris 24PC 30PC boiler sides See section 6 for detail Do not store flammable material or liquids near the boiler 200 ut k ND I 300 _ GENERAL DESCRIPTION OF THE BOILER The boiler is a combined domestic hot water and central heating appliance Its Interna
53. re at the faucet Hot water will Page 8 09 continue to flow until the faucet 1s closed and the boiler automatically shuts down Note that the pump will continue to run for a further 10secs to dissipate the residual heat from the boiler 44 DOMESTIC HOT WATER AND CENTRAL HEATING MODE O When heating demand is required 1 e the timer and thermostat are calling for heat then providing the power is on the boiler will fire automatically An integral pump is then energised and hot water from the boilers primary circuit is circulated around the central heating systems pipe work and radiators When the demand for central heating is no longer present either the thermostat reaches temperature or the time clock reaches the end of its set period the burner will shut down and the boiler will revert to stand by waiting to respond to the next heating or hot water demand The pump will continue to operate for a short period of time to dissipate any excess heat from within the boiler s heat exchanger If during the heating period there is a call for hot water this will take preference over heating When satisfied the boiler will then supply the heating demand as required Note there may be a 45sec delay depending on how the boilers dipswitches are set See section 14 3 for details solaris 24PC 30PC It is important to keep the boiler clear of dust during the installation In particular do not allow debris to enter the top of the bo
54. rn off and isolate electrical supply a Remove interface cover by lifting the two latches figure 33 a Remove the electrical connections to the PCB taking note of where the connections are fitted by releasing the clips and carefully pulling off the connectors Release the 5 screws securing the PCB to the control panel and lift out the PCB a Hi the replacement PCB in reverse order of removal ensuring that the PCB electrical connections are fully pushed home a Check that the on board adjustments to the same value as the old PCB Re set as necessary ref section 15 1 Figure 33 18 8 Pump a The order of removal is different dependant on the failure of the motor or plastic body In case of motor failure a Drain the boiler s hydraulic circuit as detailed in 18 2 Disconnect the screws connecting the pump motor to the body figure 34 a Pul out the motor and disconnect the electrical connections from the pump cable housing u solaris 24PC Figure 34 Figure 35 Fit the replacement motor in reverse order ensuring the correct polarity of the electrical connections Open the isolating valves on the flow and return connections refill vent and re pressurise the water system ensuring the pump union joints are sound In case of body damage Page 28 Remove the motor described above Remove the secondary heat exchanger as detailed in 18 9 R
55. se to your body as possible Where possible transport the boiler using a suitable trolley sack truck or get some assistance Grip the boiler firmly and before lifting establish where the weight 15 concentrated to determine the centre of gravity repositioning yourself if necessary To remove the appliance 1 Carefully slit or remove the sealing tape being careful not to scratch the appliance door 2 Fully open the carton lid and remove the condensate hose and mounting bracket Roll the carton onto its open face Lift the carton free of the inner packaging 5 Remove and valve package and instructions 6 Stand the boiler on its base within the styrene block and remove the top packaging piece 7 If you wish to remove the styrene base lie the appliance on its back to do so 8 Read the instructions carefully before installation of the appliance pus 10 2 Prior to installing the boiler check the contents of the carton Appliance Valves Condensate hose Wall Hanging Bracket Mounting Template Service Installation and User Manual which includes the Benchmark Log Book and Guarantee Card The boiler dimensions are given in figure 9 Page 17 solaris 24PC 30PC Figure 9 4 M 430 mm RU Z B 128 mm pm Figure 10 9 i i d Bottom Fixing Jig Optional L 8 10 4 Position the supplied template on the wall ensuring it is level both verticall
56. sioning the system via the pressure relief valve may Tips leave debris on the valve seat allowing water to e The installer shall instruct the user in the seep after you have left the job This will cause operation of the boiler safety devices contained within the boiler and instruction on how to re pressurise the system if the water pressure falls The installer should then hand over the instructions and completed Benchmark Logbook The user should be instructed to keep the instructions and logbook in a safe place for servicing and future reference Page 9 the boiler to lose pressure and the boiler to lockout The boiler is fitted with inlet filters both on the cold water inlet and the central heating return If you are unable to obtain hot water at the faucet it 1s likely that the cold water inlet valve filter has become blocked whilst blockage of the filter on central heating return valve will cause the heater to lock out at the overheat thermostat as the water flow is reduced e f you are able to obtain hot water but not heating it is also advisable to check the clock connections and that the room thermostat and time clock are calling for heat e Remember that after hot water draw off there 15 a 45 sec delay before the heating will fire up if No 3 dipswitch is in the OFF position see fig 19 on page 27 e When commissioning the boiler check the inlet pressure is at 20mbar and burner pressure against the Technical data on
57. st be completed 17 3 Prior to servicing check the flue operation terminal guard if fitted and the boilers operation 17 4 Ensure that both the electrical and gas supplies to the boiler are isolated before commencing service of the boiler 17 5 Remove the boiler casing as follows O Open the front panel by removing two screws at the bottom of the boiler figure 23 Page 24 23 solaris 24PC 30PC Figure 25 17 7 Disconnect the electrical leads and gas valve pipe connection from the fan disconnect at the gas valve taking care not to damage the restrictor remove the fan securing screws Figure 26 Figure 27 17 6 Release the hermetic chamber cover by removing the two screws figure 24 and then lifting the cover to release it from the retaining hooks at the top of the boiler Figure 24 17 8 Remove the burner assembly from the combustion chamber as follows a Disconnect and remove the gas supply pipe between the gas valve and fan taking care not to damage the restrictor In the top of the gas valve Release the side panels by removing the screws on the upper and lower sides figure 25 Remove the panels by swinging them out and lifting them up Fi 28 igure a Pull off the ignition and flame electrode leads from the PCB and ignition transformer and remove the wires through the grommet on the lower combustion chamber Remove the burner retaining nuts and extract the burn
58. st be sited with minimum clearances as specified in Figure 3 Note if pluming becomes problematic or causes a nuisance a plume management kit is available from your stockist 7 2 Current regulations and standards require a terminal guard to be fitted where the terminal 1s accessible to touch or at risk of being damaged All wall mounted terminals sited within 2m of the level which people have normal access should be adequately protected with a suitably sited guard 7 3 Where the flue terminates within 1m of a plastic or painted gutter or within 500mm of painted eaves then protection should be provided in the form of an aluminium shield at least 1m in length fitted to the underside of the gutter or painted surface 7 4 The flue should not be sited where the condensate plume may give rise to a nuisance factor under certain weather conditions NOTE If you have difficulty siting the flue in an appropriate location your supplier will be happy to supply anti plume management kit which discharges the flue products at a higher level or a deflection elbow which deflects the plume to the left or right Page 12 solqris 24PC A 1 E Q9 B C lG M pia D M F amp 74 i K E F F mr HI Figure 3 Directly below an openable window or other opening e g air brick 300 mm B Below gutters soil pipes or drain pipes 75 mm Below eaves 200 mm D Below balconies or car front r
59. state where the filling loop can be found system for future reference Please instruct the user how to top up the system water pressure L 20mm 10 17 Connect the domestic hot water cold water Inlet heating system flow amp return and pressure k tk fittings ensuring that the pipework has been AL correctly power flushed before final connection L relief valve pipework to the supplied boiler i Y 10 18 Condensing boilers of this type must have the condensate drain connected to drainage system Due to the acidic nature of the condensate Figure 15b the drainage system must be made of non corrosive material such as plastic tubing Condensate should if possible be discharged into the internal household draining system If this 1s L not practical discharge can be made externally into the household drainage system or a purpose designed soak away containing lime chippings Note if a soak away is used the drain must E d terminate at least 500mm from the external wall 10 19 The electrical connections to the boiler must be in accordance with Section 9 of these instructions esse E baa to TSS F lt B 11 Gas Supply 11 1 The gas supply pipe must be of 22mm copper from the meter to the boiler and capable of delivering the quantity of gas required by the boiler see Technical Data section 2 1n addition to the demand of any other gas appliances being serviced from that supply
60. switch opens cutting off the electrical supply to the gas valve and causing the boiler to Lock out Once activated the boiler has to be manually re set Refer to section 13 2 solaris 24PC 30PC 16 3 The boiler s control unit has an in built frost protection device that fires the boilers burner when the temperature of the primary hydraulic water falls below 6 C The device works irrespective of any room thermostat setting and will protect the complete heating system Once the water temperature reaches 16 C the boiler reverts back to normal operation 16 4 If there is a fault on the DHW sensor the boiler continues to operate by controlling DHW outlet temperature by using the CH temperature sensor which limits the water temperature at 65 during DHW operation If such a failure occurs a fault code will be displayed on the LCD display please contact your service agent 17 Routine Servicing 17 1 To ensure the continued efficient and safe operation of the boiler it is recommended that it 1s checked and serviced regularly The servicing must be carried out by a competent person in accordance with the Gas Safety and Use Regulations The frequency of servicing will depend upon the particular installation conditions and usage but in all cases the boiler must be serviced at least once a year 17 2 Following servicing of the boiler the relevant sections of the Benchmark Installation Commissioning and Servicing Log Book mu
61. the above options are possible then condensate must be discharged into a purpose designed soakway It is recommended that any external condensate pipe is insulated and increased to 32mm diameter in order to prevent the condensate from freezing 6 7 For compartment Installation the requirements of BS6798 and BS5440 Part 2 must be met gt The compartment must be of sufficient size to permit access for inspection and servicing or the removal of the boiler and any ancillary equipment gt Any space used for airing clothes or storage must be separated from the appliance by a non combustible partition Where the partition is formed from perforated material then the major dimension of the apertures shall not exceed 13mm gt No combustible surface must be within 20mm of the boiler casing without protection There must be 20mm clearance between the compartment door and boiler case gt Where the boiler s flue pipe passes through the airing space it must be protected by a non combustible sleeve or fire stop having a minimum clearance of 20 mm between the flue pipe and sleeve In addition if the flue pipe passes through the partition then the clearance gap of the flue pipe or its guard with the partition must not exceed 13 mm 6 8 When the boiler 1s intended for use with LPG it must not be installed in a room or internal space below ground level solaris 24PC 30PC 7 Flue Terminal Location 7 1 The flue terminal mu
62. y and horizontally figure 10 Mark the boiler fixing jig locations if used wall bracket fixing positions and flue outlet position rear flue only For flue side exit from the boiler Mark the horizontal flue centre line on the rear wall Extend the horizontal line to the side wall allowing a 3 decline back towards the boiler to enable condensate to drain back through the boiler Mark the flue centre line figure 11 Figure 11 vertical Centre Distance to the flue centre line 10 5 When cutting the flue hole it is recommended that a 105mm diameter core drill is used where both internal and external access for the flue installation is available Where only internal access is available a 125mm diameter core drill should be used Note Please take adequate precautions to prevent debris entering the boiler via the flue outlet 10 6 Using 8 5mm drill bit drill the holes for fixing jig optional and hanging bracket Locate and secure the supplied wall mounting bracket and fixing jig if obtained in position figure 12 Figure 12 solaris 24PC 30PC 10 7 Mount the boiler onto the fixing bracket via the boiler mounting tabs figure 12 10 8 Connect the isolation valves to the boiler ensuring the filter valve 1s at the extreme right and the sealing washers are fitted correctly 10 9 On installing the flue determine the required length of the outer air duct by measuring the d

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